AU752076B2 - Multistep building entryway barrier floor covering combination - Google Patents

Multistep building entryway barrier floor covering combination Download PDF

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Publication number
AU752076B2
AU752076B2 AU94174/98A AU9417498A AU752076B2 AU 752076 B2 AU752076 B2 AU 752076B2 AU 94174/98 A AU94174/98 A AU 94174/98A AU 9417498 A AU9417498 A AU 9417498A AU 752076 B2 AU752076 B2 AU 752076B2
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AU
Australia
Prior art keywords
barrier combination
vinyl
building
carpet
entryway
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AU94174/98A
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AU9417498A (en
Inventor
Thomas D. Nord
James N. Rockwell Jr
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Milliken and Co
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Milliken and Co
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Publication of AU9417498A publication Critical patent/AU9417498A/en
Assigned to MILLIKEN & COMPANY reassignment MILLIKEN & COMPANY Alteration of Name(s) of Applicant(s) under S113 Assignors: MILLIKEN RESEARCH CORPORATION
Application granted granted Critical
Publication of AU752076B2 publication Critical patent/AU752076B2/en
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Classifications

    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47LDOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L23/00Cleaning footwear
    • A47L23/22Devices or implements resting on the floor for removing mud, dirt, or dust from footwear
    • A47L23/26Mats or gratings combined with brushes ; Mats
    • A47L23/266Mats
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47LDOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L23/00Cleaning footwear
    • A47L23/22Devices or implements resting on the floor for removing mud, dirt, or dust from footwear
    • A47L23/26Mats or gratings combined with brushes ; Mats
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00Layered products comprising a layer of natural or synthetic rubber
    • B32B25/10Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0073Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as an aqueous dispersion or latex
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0086Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing characterised by the cushion backing, e.g. foamed polyurethane
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/02Synthetic macromolecular fibres
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/02Synthetic macromolecular fibres
    • D06N2201/0254Polyolefin fibres
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/02Synthetic macromolecular fibres
    • D06N2201/0263Polyamide fibres
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/10Conjugate fibres, e.g. core-sheath, side-by-side
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00Macromolecular materials of the coating layers
    • D06N2203/02Natural macromolecular compounds or derivatives thereof
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00Macromolecular materials of the coating layers
    • D06N2203/04Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/045Vinyl (co)polymers
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00Macromolecular materials of the coating layers
    • D06N2203/04Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/045Vinyl (co)polymers
    • D06N2203/048Polyvinylchloride (co)polymers
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00Macromolecular materials of the coating layers
    • D06N2203/06Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/068Polyurethanes
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2207/00Treatments by energy or chemical effects
    • D06N2207/04Treatments by energy or chemical effects using steam
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00Properties of the materials
    • D06N2209/08Properties of the materials having optical properties
    • D06N2209/0807Coloured
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00Properties of the materials
    • D06N2209/16Properties of the materials having other properties
    • D06N2209/1664Releasability
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00Specially adapted uses
    • D06N2211/06Building materials
    • D06N2211/066Floor coverings

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Floor Finish (AREA)
  • Artificial Filaments (AREA)
  • Carpets (AREA)

Description

V.
Y
AUSTRALIA
Patents Act COMPLETE SPECIFICATION
(ORIGINAL)
Class Int. Class Application Number: Lodged: Complete Specification Lodged: Accepted: Published: Priority Related Art: ego.
S
S
OSSS
0 00 S 0
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0
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Name of Applicant: Milliken I ser.h o, rti Actual Inventor(s): Thomas D. Nord James N. Rockwell, Jr Address for Service: PHILLIPS ORMONDE FITZPATRICK Patent and Trade Mark Attorneys 367 Collins Street Melbourne 3000 AUSTRALIA Invention Title: MULTISTEP BUILDING
COMBINATION
Our Ref 562121 POF Code: 28355/28355 ENTRYWAY BARRIER FLOOR COVERING The following statement is a full description method of performing it known to applicant(s): 1 of this invention, including the best IP AUSTRALIA
RECEIVED
S,2 7 NOV 1998
MELBOURNE
MULTISTEP BUILDING ENTRYWAY BARRIER FLOOR COVERING COMBINATION Field of the Invention This invention relates to a combination of floor coverings arranged in and around an entryway to a building in order to provide effective moisture, dirt, and debris removal from the footwear of pedestrians entering such a building. More particularly, this combination comprises at least three floor covering articles placed inside and outside an entryway of a building and having reduced amount of coarse filament the closer to and further inside the entryway such articles are placed. An alternate arrangement involving a building having an airlock-type vestibule configuration is also provided.
Discussion of the Prior Art The discussion of the background to the invention herein is included to explain the context of the invention. This is not to be taken as an admission that any of the material referred to was published, known or part of the common general knowledge in Australia as at the priority date of any of the claims.
Floor mats have long been utilized to facilitate the cleaning of the bottoms of people's shoes. Moisture, dirt, and debris from out of doors easily adhere to such footwear, particularly in inclement weather and particularly in areas of grass or mud or the like. Such unwanted and potentially floor staining or dirtying objects need to be removed from a person's footwear prior to entry indoors. In response, floor mats, in particular those having a tufted carpet pile comprised solely of coarse filaments, were developed which provide an easy i manner of cleaning the soles of a person's shoes simply by scraping the footwear against such a stiff article. Examples of such floor mats are 'exemplified in U.S. Patents 1,008,618, to Skowronski et al., 4,045,605 to Breens et oo
*SS.
-2al., and 4,353,944, to Tarui, as well as French Patent No. 1,211,755, assigned to Cosyntex and PCT Application 95/30040, assigned to Kleen-Tex Industries, Inc.
Further improvements over the basic all-coarse filaments mats included interspersed coarse and fine carpet pile yarns, either in stripe, or checkerboard patterns, as taught by U. S. Patents 4,820,566 and 5,055,333, both to Heine et al., or in separate regions of the same article, as in Tarui, above. One notable development is found in U.
S. Patent 2,599,049, to Dollinger. This reference teaches an inside vestibule mat having three separate regions of decreasing amounts of coarse filament. Also integral within this article are a heating system for drying the moisture, mud, etc., on the floor mat, and a drawing exhaust system beneath the mat for removing such dried matter from the mat without the need of displacing the mat itself. All of the aforementioned patents documents are incorporated herein by reference. Nowhere in the prior art is a system of three separate floor covering articles disclosed or fairly suggested which must be placed in specific locations relative to a building's entryway, which have specific amounts of coarse and/or fine carpet pile yarns, and which are removable from their respective building locations for industrial wash processing.
o o Therefore, a need exists for an improved, easily laundered or cleaned, effective moisture, dirt, and debris removal entry barrier combination.
eoeeoa o° a *oa.
ao a 2a Description of the Invention An object of the present invention is to provide a building entryway barrier which overcomes, or at least alleviates, one or more disadvantages of the prior art.
According to the present invention, there is provided a building entryway moisture, dirt and debris barrier combination including at least three separate floor or ground covering articles A, B, and C; wherein A is placed inside said building entryway, C is placed outside said building entryway, and B is either placed inside said building entryway, at a location closer to said building entryway than A, or outside said building entryway, at a location closer to said building entryway than C; wherein C is a ground covering mat product comprised of completely tufted carpet pile of 100% heavy denier monofilament carpet yarn and a backing selected from the group consisting substantially of vinyl, rubber, and latex; wherein B is a floor or ground covering mat product comprised of completely tufted carpet pile having a lower percentage of heavy denier monofilament carpet yarn than C and a backing selected from the group consisting substantially of vinyl, rubber, and latex; and wherein A is a floor covering mat, broadloom, or tile product comprised of 20 completely tufted carpet pile having a lower percentage of heavy denier monofilament yarn than B and a backing selected from the group consisting substantially of rubber, polyvinyl chloride, vinyl, and urethane.
The present invention also provides a building entryway moisture, dirt and debris barrier combination for a building entryway having an air-lock type vestibule configuration including at least three separate floor or ground covering articles A, B, and C; .wherein A is placed inside said building entryway and is not placed within said airlock-type vestibule, B is placed within said airlock-type vestibule, and C is placed outside said building entryway; S 30 wherein C is a ground covering mat product comprised of completely tufted carpet pile of 100% heavy denier monofilament carpet yarn and a backing selected from the group consisting substantially of vinyl, rubber, and latex; wherein B is a floor or ground covering mat product comprised of ompletely tufted carpet pile having a lower degree of heavy denier 2b monofilament carpet yarn than C and a backing selected from the group consisting substantially of vinyl, rubber, and latex; and wherein A is a floor covering mat, broadloom, or tile product comprised of completely tufted carpet pile having a lower percentage of heavy denier monofilament yarn than B and a backing selected from the group consisting substantially of rubber, polyvinyl chloride, vinyl, and urethane.
Accordingly, one advantage of the invention is a building entry barrier combination of at least three floor or ground covering articles having decreasing degrees of coarse filament carpet pile compositions relative to each article's placement from further to nearer to within the building entryway. A further advantage is a multistep entry barrier system which comprises easily removable and easily launderable floor covering articles. A still further advantage is the provision of a series of footwear scraping articles which more easily and more thoroughly removes moisture, dirt, and debris from a person's shoes. Yet another advantage is the provision of an entry barrier combination of floor covering articles as noted a.
o a :\mary\MMHNODEL\94174-98.doc 3 above wherein one article is located outside an entry of a building, one is located inside an airlock-type entry vestibule but outside the main part of a building, and one article is located just inside the airlock-type entry vestibule of a building.
The term building pursuant to this invention encompasses such structures as an office building, hotel, store, apartment complex, house, and the like; basically any manmade structure which requires a relatively heavy amount of pedestrian traffic. The term entryway for this invention simply means the area of ingress and/or egress from such a building. Generally, such an area separates the inside of a building from the outside of a building through the use of a door, which can be of any type wooden, glass, revolving, sliding, and the like). Furthermore, such a building may comprise an airlocktype vestibule which is simply an enclosed area between an outer door, which leads to the outside of the building, and an inner door, which leads to the inside of the building.
Such outer and inner doors may be, again, any type or make.
The barrier combination of this invention is utilized to facilitate and effectuate the removal of moisture, dirt, and debris from the footwear of pedestrians entering such a building. This combination is arranged in the manner or manners specified below whereupon the shoe-sole cleaning ability of each separate article within this combination o.
W:\mary\MMHNODEL\94174-98.doc -4diminishes as a pedestrian nears and ultimately enters the building. Each separate article can easily be removed from the floor or ground and can be easily laundered through, preferably, industrial washing processes, although hand washing and any other type of cleaning may be utilized, also.
The inventive combination includes, as noted above, at least three floor or ground covering articles, A, B, and C. These articles are preferably arranged in and e~g@ around a building entryway wherein the article or articles located outside the entryway S.g ohave greater amounts of heavy denier coarse monofilament carpet yarns than does the •o•0o article or articles located inside the entryway. In this manner, more moisture, dirt, and o00 10 debris can be removed from a person's footwear as such a pedestrian is outside the building stepping on the coarser article, while residual amounts are removed by the less S* coarser articles leading into and located inside the building. In particular, A is a floor covering placed inside a building entryway, C is a ground covering article placed outside S* a building entryway, and B is either a floor covering article placed inside the entryway, but closer to the entryway than A, or B is a ground covering article placed outside the
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entryway, but closer to the entryway than C. Thus, C, having completely tufted pile completely comprising heavy denier coarse monofilament carpet yarn, has a higher percentage of such heavy denier coarse yarn than does B, and B has a higher percentage of such carpet yarn than does A. Preferably, B has completely tufted pile comprising, as merely an example, from about 30 to about 60% tufted heavy denier coarse monofilament carpet yarn and 40 to 70% fine denier carpet yarn, and A has completely tufted pile comprising, for example, from about 10 to about 20% heavy denier coarse carpet yarn and from about 80 to about 90% fine denier carpet yarn. Other additional floor or ground covering articles may be present as long as each additional article has a lower percentage of coarse carpet yarn in the same type of series as set forth above.
Another preferred arrangement is provided when the building entryway includes an airlock-type vestibule configuration. In such a scenario, A is placed inside the building, but not within the vestibule, B is a floor covering article placed inside the vestibule, and C is placed outside the building. In this and the aforementioned preferred arrangement, C is placed directly adjacent to, or within a reasonably close proximity of, fees S• ••the entryway or the outer door, such as between 0 and 6 feet. Preferably, C abuts the 9:000: •,outer door itself 0 feet away); however, if B is also placed outside the building, *0* 0 10 then B is preferably abuts the entryway or outer door and C is preferably placed directly adjacent to B. Of course, B may be placed as far away as 6 feet from the entryway or the outer door and C may be placed as far away as 6 feet from B, if desired. Where A is concerned, it is also placed within a reasonably close proximity to the entryway or inner ow••• door (0 to 6 feet away), and preferably abuts such an entryway; however, if B is placed inside the entryway, then it is placed within a reasonably close proximity to said inner door, preferably abutting it, and A is placed within a similar distance to B. IfB is placed within an airlock-type vestibule, then it may be placed at any distance from either the inner or outer door.
A noticeable benefit of this combination is the ability for the majority of the potential moisture, dirt, and debris from pedestrians' shoes to remain, through removal by the coarser carpet yam, outside such a building. Since the smaller, residual amounts of such liquids and/or solids would then be removed by the other less coarse mats, the chance of transferring such unwanted matter into the building are thereby reduced. The -6coarse fibers on each floor covering or ground article must also have the ability to retain the dirt, moisture, and debris removed from pedestrian footwear within the body of the article. In this fashion, the removed and retained matter cannot be transferred to the shoes of a subsequent pedestrian, thus preventing the potential "re-tracking" of moisture, dirt, and debris through the building. A more effective way of cleaning and scraping a pedestrian's shoes as well as ensuring the building's interior will remain clean are thus provided.
Additionally, such a system permits a more pleasing aesthetic effect within a obuilding entryway since myriad patterns and colorations can be utilized on the 10 aforementioned floor or ground covering articles. Furthermore, and as noted above, the a. floor or ground covering articles are easily removable themselves from their locations so S. °as to be easily laundered or washed. Such a benefit facilitates the cleaning of such floor or ground coverings in order to ensure the aesthetic characteristics desired remain and •°•oo allows for reduced amounts of residue to be carried by a pedestrian's footwear subsequent to traversing such articles.
The articles A, B, and C are each, in one preferred embodiment, produced in mat form having the requisite flexibility to withstand the aforementioned industrial laundering processes. Such mats are generally comprised of a tufted carpet pile attached to a vinyl, latex, or vulcanized rubber sheet as exemplified in U.S. Patents 3,306,808, to Thompson et al., 4,741,065, to Parkins, 4,886,692, to Kerr et al., 5,227,214, to Kerr et al., 5,240,530, to Fink, and 5,305,565, to Nagahama et al., all hereby entirely incorporated by reference. Such an attachment can be accomplished during the actual vulcanization step, as taught in Nagahama, for example, above, or through the use of an adhesive layer, preferably a polyolefin adhesive, between the carpet pile and the rubber sheet, as disclosed in copending U.S. Patent Application 08/73 2,866, all such references herein being entirely incorporated by reference. A particularly notable reference is PCT Application 96/37645, to Milliken Denmark, which discloses suitable coarse fiber mat products, herein incorporated by reference.
In another preferred embodiment, B and C are produced in mat form while A is 9:00 produced in broadloom form. Such a form encompasses extra-wide and long carpets, so: or, in other words, carpets which are regularly placed wall-to wall in hallways, rooms, C and the like. Such broadloom products are manufactured on a extra-wide loom and may 0:0 10 be colored through any standard process jet-dyeing, immersion, spraying, etc.).
Such a floor covering may be applied to a floor with an easily dissolvable adhesive to 0 facilitate its removal therefrom. Also, and to the contrary, such carpet may be cleaned C while remaining at its location through the use of any standard, well-known wet-, dry, or steam-cleaning process for carpet. These broadloom products may have backings made from polyvinyl chloride, vinyl, or urethane (which provides improved cushioning).
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In yet another preferred embodiment, B and C are produced in mat form while A is produced in tile form. Such a form is exemplified in U.S. Patent 5,545,276, to Hi-ggins, entirely incorporated herein by reference. Carpet tiles of this sort are easily removable and thus can be easily cleaned at a remote location. Furthermore, such a 2 0 product can be patterned or colored through any well-known process (such as jetdyeing, etc.) in such a way as to provide a tile or group of tiles which is or are both integral aesthetically to and functionally with the remaining tiles of the particular room, hall, oyer, etc. The preferred embodiment contemplates a -8single large tile or a group of tiles which appear and match the same pattern as the other carpet tiles but include the requisite amount of heavy denier coarse monofilament carpet yarn while the remaining tiles do not comprise such a heavy denier component.
Furthermore, such tile products may have backings made from polyvinyl chloride, vinyl, or urethane (which provides improved cushioning).
Each of the articles A, B, and C can be of any standard size for mats, and A may be of any standard size for broadloom or tile products. More succinctly, if the article is oa mat, any size from roughly 2 feet by 2 feet to about 4 feet by 8 feet is preferred.
Larger and smaller sizes are also contemplated. If A is a broadloom product, preferably oo: 10 it is ofa size from about 2 feet by 3 feet to about 6 feet by 10 feet. Again, other sizes, both larger and smaller are possible. If A is a tile product, each individual tile, from about 18 inches by 18 inches to about 36 inches by 36 inches, may comprise the entire article contemplated. However, groupings of such tiles may be utilized also. For instance, a configuration of 2 tiles in three rows (72 inches by 108 inches) may comprise °ooo• article A. Generally, the largest grouping of tiles would equal an area total of about 108
V.
see inches by 180 inches; smaller areas of tile groupings are thus also contemplated within this invention.
The term denier, as it applies to yarns, refers to the weight of a fiber having a length of 9,000 meters. Heavy, coarse fibers generally have a range of deniers from about 100 to about 5,000 denier per filament The preferred range is from about 100 to about 2,000 dpf, and most preferred is a range of from about 150 to about 1,000 dpf Fine fibers generally have a range of deniers from about 0.1 to about 100 dpf, preferably from about 1 to about 50 dpf, and most preferred from about 5 to about -9dpf The actual yarns utilized within this invention for each of the articles A, B, and C are completely tufted on the carpet pile.
The specific heavy denier coarse monofilament carpet yarns may be made from polypropylene, polyester, nylon 6, nylon 6,6, or any combinations thereof Preferably, such yarns are made of polypropylene. Such coarse fibers may be formed either of single component filaments or of two-component sheath/core filaments having a core of one material enclosed within a sheath of a second material. The core may be formed of a single filament or of a filamentous yam and may be coated with thermoplastic materials, such as polyvinyl chloride. The specific fine denier carpet yarns may 10 be made from nylon 6, nylon 6,6, acrylic, regenerated cellulose, wool, polyester, cotton, propylene, or any combinations thereof Preferred are polyester, nylon 6, nylon 6,6, or combinations thereof Both the coarse and fine fibers may be tufted and attached to a carpet backing in any conventional manner, such as those noted in the aforementioned, 0@o@*S Stherein incorporated U.S. Patents to Heine et al. and Higgins et al., and therein •oooo incorporated PCT Applications to Kleen-Tex Industries, Inc. and Milliken Denmark.
For articles A and B, the configuration of fine and coarse fibers may be arranged in any pattern. Preferably, such patterns are striped one line of coarse fibers running longitudinally from one end of an article to the other end followed by a line of fine fibers following suit, with a repeated pattern of coarse and fine fiber lines). Other preferable and possible patterns include checkerboard, diamond-shapes, and the like; basically, and again, any possible pattern is contemplated as long as the requisite degree of coarseness is retained for each of articles A and B.
Brief Description of the Invention FIG. 1 is an aerial view of the inventive barrier combination wherein B is located outside the building entryway.
FIG. 2 is an aerial view of the inventive barrier combination wherein B is located within the building entryway.
FIG. 3 is an aerial view of the inventive barrier combination wherein B is located 4 *within an airlock-type vestibule.
While the invention will be described and disclosed in connection with certain *sees: preferred embodiments and procedures, it is by no means intended to limit the invention 10 to such specific embodiments and procedures. Rather, it is intended to cover all such alternative embodiments, procedures, and modification thereto as may fall within the true spirit and scope of the invention as defined and limited only by the appended claims.
oo.
Detailed Description of the Drawings and Preferred Embodiment of the Invention In FIG. 1, a building entryway is shown wherein there is a door 16 and a wall 15 14, -both of which separate the exterior from the interior of a building (not illustrated).
A floor mat 10 (which is article C, above), which comprises 100% tufted heavy denier coarse monofilament carpet yarn (propylene with denier of about 150 dpf), is placed outside the building entryway at a location about 4 feet from the door 16, further from the door 16 and wall 14 than is floor mat 12 (article B, above), which comprises about 50% heavy denier coarse monofilament carpet yarn (polypropylene with denier of about 150 dpf) and about 50% fine denier carpet yarn (nylon 6,6 with denier of about 1).
Article C 10 is thus located about 1 foot from article B 12, which is about 1 foot from -11the door 16. Floor mat 18 (article A, above) which comprises about 10% heavy denier coarse monofilament carpet yarn (polypropylene with denier of about 150 dpf) and about 90% fine denier carpet yarn (nylon 6,6 with denier of about is located within the building entryway, about 1 foot from the door 16. All of mats 10, 12, and 18 are rectangular in shape with mats 10 and 12 having areas of about 2 feet by 3 feet. Mat 18 has a size of about 6 feet by 9 feet.
As illustrated in FIG. 2, the mats 10, 12, and 18, having the same dimensions as a in FIG. 1, above, are arranged in a configuration wherein mat 12 is located inside the 0 building entryway, about 1 foot from the door 16, at a location closer to the door 16 .*oo 10 and wall 14 than mat 18, which is about 4 feet from the door 16 and 1 foot from article B 12.
An airlock-type vestibule configuration is illustrated in FIG. 3 wherein article B 12 is located inside a door 16 and a wall 14 but outside another door 22 and another 000e S" wall 20. Article B 12 is thus about 6 inches from the outside door 16 and about 6 0 inches from the inside door 22. All of mats 10, 12, and 18 have the same dimensions as 0 for FIGs. 1 and 2, above. Article C 10 remains at a location outside of the building entryway, about 1 foot away from the door 16, and article A 18 remains at a location inside of the building entryway, at a location further inside the building than the airlocktype vestibule formed by doors 16 and 22 and walls 14 and 20, about 1 foot from the door 22.
It is, of course, to be appreciated that while several potentially preferred embodiments have ben shown and described, the invention is in no way to be limited thereto, since modification may be made and other embodiments of the principles of this -12invention will occur to those skilled in the art to which this invention pertain.
Therefore, it is contemplated by the appended claims to cover any such modifications and other embodiments as incorporate the features of this invention within the true spirit and scope thereof *o t@ 0 @0 *08
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0* 0 0* e S* *e Ssee*
C
I

Claims (15)

1. A building entryway moisture, dirt and debris barrier combination including at least three separate floor or ground covering articles A, B, and C; wherein A is placed inside said building entryway, C is placed outside said building entryway, and B is either placed inside said building entryway, at a location closer to said building entryway than A, or outside said building entryway, at a location closer to said building entryway than C; wherein C is a ground covering mat product comprised of completely tufted carpet pile of 100% heavy denier monofilament carpet yarn and a backing selected from the group consisting substantially of vinyl, rubber, and latex; wherein B is a floor or ground covering mat product comprised of completely tufted carpet pile having a lower percentage of heavy denier monofilament carpet yarn than C and a backing selected from the group consisting substantially of vinyl, rubber, and latex; and wherein A is a floor covering mat, broadloom, or tile product comprised of completely tufted carpet pile having a lower percentage of heavy denier monofilament yarn than B and a backing selected from the group consisting substantially of rubber, polyvinyl chloride, vinyl, and urethane. S2. The barrier combination of claim 1 wherein B includes from 30 to 60 heavy denier coarse monofilament carpet yarn and from 40 to 70% fine denier carpet yarn; and A includes from 10 to 20% heavy denier coarse monofilament carpet 25 yarn and from 80 to 90% fine denier carpet yarn.
3. The barrier combination of claim 1 or 2, wherein A is a mat product having a backing selected from the group consisting substantially of vinyl and ••ell= rubber.
4. The barrier combination of claim 1 or 2, wherein A is a broadloom product having a backing selected from the group consisting substantially of polyvinyl chloride, vinyl, and urethane. 14 The barrier combination of claim 1 or 2, wherein A is a tile product having a backing selected from the group consisting substantially of polyvinyl chloride, vinyl, and urethane.
6. The barrier combination of any preceding claim, wherein B is located inside said building entryway.
7. The barrier combination of any one of claims 1 to 5, wherein B is located outside said building entryway.
8. The barrier combination of claim 3, wherein A is a mat product having a backing material of rubber.
9. The barrier combination of claim 4, wherein A is a broadloom product having a backing material of urethane. The barrier combination of claim 5, wherein A is a tile product having a backing material of urethane.
11. A building entryway moisture, dirt and debris barrier combination for a building entryway having an air-lock type vestibule configuration including at least three separate floor or ground covering articles A, B, and C; wherein A is placed inside said building entryway and is not placed within i: .said airlock-type vestibule, B is placed within said airlock-type vestibule, and C is placed outside said building entryway; **wherein C is a ground covering mat product comprised of completely tufted carpet pile of 100% heavy denier monofilament carpet yarn and a backing selected from the group consisting substantially of vinyl, rubber, and latex; wherein B is a floor or ground covering mat product comprised of S 30 completely tufted carpet pile having a lower degree of heavy denier monofilament carpet yarn than C and a backing selected from the group consisting substantially of vinyl, rubber, and latex; and wherein A is a floor covering mat, broadloom, or tile product comprised of completely tufted carpet pile having a lower degree of heavy denier monofilament yarn than B and a backing selected from the group consisting substantially of rubber, polyvinyl chloride, vinyl, and urethane.
12. The barrier combination of claim 11, wherein B includes from 30 to 60 heavy denier coarse monofilament carpet yarn and from 40 to 70% fine denier carpet yarn; and A includes from 10 to 20% heavy denier coarse monofilament carpet yarn and from 80 to 90% fine denier carpet yarn.
13. The barrier combination of claim 11 or 12, wherein A is a mat product having a backing selected from the group consisting substantially of vinyl and rubber.
14. The barrier combination of claim 11 or 12, wherein A is a broadloom product having a backing selected from the group consisting substantially of polyvinyl chloride, vinyl, and urethane. The barrier combination of claim 11 or 12, wherein A is a tile product having a backing selected from the group consisting substantially of polyvinyl 20 chloride, vinyl, and urethane.
16. The barrier combination of claim 13, wherein A is a mat product having a backing material of rubber. 25 17. The barrier combination of claim 14, wherein A is a broadloom product having a backing material of urethane.
18. The barrier combination of claim 15, wherein A is a tile product having a backing material of urethane. S
19. The barrier combination of any one of claims 1 to 18, wherein the heavy denier coarse monofilament carpet yarns are made of polypropylene having a Sdenier range of from 100 to 2,000 dpf. The barrier combination of any one of claims 1 to 18, wherein the heavy denier coarse monofilament carpet yarns are made of polypropylene having a denier range of from 100 to 200 dpf.
21. A building entryway moisture, dirt, and debris barrier combination substantially as herein described with reference to any one of the embodiments illustrated in the accompanying drawings. DATED: 31 January 2002 PHILLIPS ORMONDE FITZPATRICK Patent Attorneys for: MILLIKEN RESEARCH CORPORATION :o**e W:\Mary\MMHNoDelete\9417498A.doc
AU94174/98A 1997-12-11 1998-11-27 Multistep building entryway barrier floor covering combination Ceased AU752076B2 (en)

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US6726975B2 (en) 2000-06-27 2004-04-27 Milliken & Company Multiple fiber floor mat and method

Citations (3)

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US2599049A (en) * 1947-07-16 1952-06-03 Lewis L Dollinger Vestibule mat and cleaning system therefor
US4711191A (en) * 1986-11-04 1987-12-08 Techniservice Monofilament-wrap texturizing method and product
US5055333A (en) * 1989-01-09 1991-10-08 Minnesota Mining And Manufacturing Company Tufted carpet

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GB1527622A (en) * 1975-06-24 1978-10-04 Smith Ass Ltd Carpeting
US4353944A (en) * 1979-11-10 1982-10-12 Hiroyuki Tarui Shoe scraper mat
GB2282965B (en) * 1993-09-14 1997-05-14 Walk Off Mats Ltd Floor mat system

Patent Citations (3)

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Publication number Priority date Publication date Assignee Title
US2599049A (en) * 1947-07-16 1952-06-03 Lewis L Dollinger Vestibule mat and cleaning system therefor
US4711191A (en) * 1986-11-04 1987-12-08 Techniservice Monofilament-wrap texturizing method and product
US5055333A (en) * 1989-01-09 1991-10-08 Minnesota Mining And Manufacturing Company Tufted carpet

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AU9417498A (en) 1999-07-01
NZ333042A (en) 2000-03-27

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